Remove Power Transfer Unit (PTU) if equipped. (refer to Power Transfer Unit 4X4 in this section)

FIG 8
Support the engine with a screw jack (1) and the transmission with a transmission jack.
Remove bell housing dust cover (3).

FIG 9
Remove four modular clutch-to-drive plate bolts (1). While removing bolts, one tight-tolerance (slotted) drive plate hole will be encountered. When this bolt is removed, mark drive plate and modular clutch assembly at this location, and be sure to align marks upon reassembly.

FIG 1
Raise the vehicle on the hoist and mark (2) driveshaft and differential (3) for proper installation.

FIG 2
Remove rear driveshaft to rear axle retaining nuts (2).

FIG 3
Remove the three bolts (3) from the center support heat shield (2).

CAUTION: Propeller shaft removal. Never allow propeller shaft to hang while connected to Power Transfer Unit (PTU), rear driveline module flanges or center bearings. If propeller shaft section is hung unsupported, damage may occur to joint, boot and/or center bearing from over-angulation. This may result in vibration/balance issues. A helper may be needed.

FIG 4
Remove the heat shield (2) and remove the two center support mounting bolts (3).

FIG 5
Remove the drive shaft (1).

Gramps

05-18-2011 05:27 PM

5 Attachment(s)

HALF SHAFTS - Front

CAUTION: Boot sealing is vital to retain special lubricants and to prevent foreign contaminants from entering the CV joint. Mishandling, such as allowing the assemblies to dangle unsupported, or pulling or pushing the ends can cut boots or damage CV joints. During removal and installation procedures, always support both ends of the halfshaft to prevent damage.

CAUTION: The halfshaft, when installed, acts as a bolt and secures the front hub/bearing assembly. If vehicle is to be supported or moved on its wheels with a halfshaft removed, install a PROPER–SIZED BOLT AND NUT through front hub. Tighten bolt and nut to 244 N·m (180 ft. lbs.). This will ensure that the hub bearing cannot loosen.

NOTE: Care must be taken not to separate the inner CV joint during this operation. Do not allow halfshaft to hang by inner CV joint, halfshaft must be supported.

FIG 4
Remove halfshaft (2) from steering knuckle by pulling outward on knuckle while pressing in on halfshaft. Support outer end of halfshaft assembly. If difficulty in separating halfshaft from hub is encountered, do not strike shaft with hammer, instead use Puller to separate.

NOTE: Removal of the inner tripod joints is made easier if you apply outward pressure on the joint as you strike the punch with a hammer. Do not pull on interconnecting shaft to remove, as the inner joint will become separated.

FIG 7
Remove the inner tripod joints (4) from the side gears of the transaxle using a punch (2) to dislodge the inner tripod joint retaining ring from the transaxle side gear. If removing the right side inner tripod joint, position the punch to the inner tripod joint extraction groove (5) (if equipped). Strike the punch sharply with a hammer to dislodge the right inner joint from the side gear. If removing the left side inner tripod joint, position the punch to the inner tripod joint extraction groove. Strike the punch sharply with a hammer to dislodge the left inner tripod joint from the side gear.

FIG 8
Hold inner tripod joint (1) and interconnecting shaft (6) of halfshaft assembly. Remove inner tripod joint from transaxle by pulling it straight out of transaxle side gear and transaxle oil seal (4). When removing tripod joint, do not let spline or snap ring drag across sealing lip of the transaxle to tripod joint oil seal. When tripod joint is removed from transaxle, some fluid will leak out.

CAUTION: The halfshaft, when installed, acts as a bolt and secures the front hub/bearing assembly. If vehicle is to be supported or moved on its wheels with a halfshaft removed, install a PROPER–SIZED BOLT AND NUT through front hub. Tighten bolt and nut to 244 N·m (180 ft. lbs.). This will ensure that the hub bearing cannot loosen.

Gramps

05-18-2011 05:29 PM

MUFFLER

WARNING: The normal operating temperature of the exhaust system is very high. Therefore, never work around or attempt to service any part of the exhaust system until it is cooled. Special care should be taken when working near the catalytic converter. The temperature of the converter rises to a high level after a short period of engine operating time.

NOTE: When replacement is required on any component of the exhaust system, you must use original equipment parts (or their equivalent). Sure :D

Raise vehicle on hoist and apply penetrating oil to band clamp nut and bolt of component being removed.

NOTE: Do not use petroleum-based lubricants when removing/installing muffler or exhaust pipe isolators (3) as it may compromise the life of the part. A suitable substitute is a mixture of liquid dish soap and water.